Gas separation contactor module and method for producing gas separation contactor module

Abstract

A method of forming a gas separation contactor module (250) includes disposing a sorbent material (120) on a membrane (110) (112); heat treating (130) the sorbent material (120) on the membrane (110) to dry the sorbent material (120); forming a unit frame (220), the unit frame comprising a perforated tube (200); forming an adsorbent unit (150) from the dried adsorbent material (120) on the membrane 110 to correspond to the unit frame (220); and, disposing the adsorbent unit (150) on the unit frame (220).

Description

Technical Field

[0001] The present disclosure relates generally to gas separation contactor modules. More particularly, the present disclosure relates to a direct air capture module and a method for making a direct air capture module for adsorptive gas separation and a system incorporating the same. Background Art

[0002] The application of adsorption gas separation processes and systems, such as temperature swing adsorption and partial pressure swing adsorption processes and separators, in adsorption gas separation in industrial processes is well known in the art. Pressure swing adsorption (PSA) is a technology for separating certain gaseous substances from a mixture of gases (usually air) under pressure based on the molecular properties of the substances and their affinity for the adsorbent material. PSA operates at near ambient temperature and is significantly different from cryogenic distillation, which is commonly used to separate gases. Selective adsorption materials (e.g., zeolites (also known as molecular sieves), activated carbon, etc.) are used as capture materials, preferentially adsorbing the target gas species at high pressure. The process is then switched to low pressure to desorb the adsorbed gas.

[0003] The temperature-vacuum shift (TVS) cycle is used to separate gaseous species from a gas mixture (typically air). TVS can be applied to amine-functionalized nanofibrillated cellulose adsorbents to simultaneously extract CO₂ and water vapor from the fluid. The effect of relative humidity on CO₂ capture capacity and the amount of co-adsorbed water was quantified.

[0004] Conventional temperature swing adsorption gas separation processes can typically employ two basic steps, an adsorption step and a regeneration or desorption step. During a typical adsorption step, a feed stream (such as a multi-component gas mixture) can be admitted to an adsorption separator and contactor containing an adsorbent material, wherein the adsorbent material can adsorb components of the feed stream and separate the adsorbed components from the remaining components of the feed stream. During a typical subsequent regeneration step, a regeneration or desorption fluid stream (e.g., a heated air or steam stream) can be admitted to the adsorption separator and contactor to increase the temperature of the adsorbent material, thereby releasing or desorbing at least a portion of the adsorbed components from the adsorbent material to provide a desorbed component and allowing recycling of the adsorbent material. Conventional adsorption gas separators typically employ a single composition of one or more adsorbent materials, such as in a conventional beaded adsorbent bed or adsorbent contactor.

[0005] One type of industrial process that may require gas separation includes combustion processes, for example, where an oxidant and a carbon-containing fuel are combusted to produce at least heat and a combustion gas stream (also known as a combustion flue gas stream). It may be desirable to separate at least one component from the combustion gas stream, including, for example, post-combustion exhaust gas treatment systems.

[0006] Over the past decade, adsorbents have been used as a class of porous materials for separation, air purification, catalysis and sensing. Metal-organic frameworks (MOFs) have become a class of adsorbents for separation, air purification, catalysis and sensing. The ability to tune the function and pore structure of MOFs allows unprecedented control at the nanoscale level, which translates into new properties at the macroscopic level. The development of MOF-based technologies depends not only on scale-related issues, but also on the ability to incorporate these highly active assemblies into industrially relevant engineered constructs (such as, but not limited to, particles and films). Active fillers for filtration and separation can include zeolites, metal oxides and carbon. Summary of the Invention

[0007] All aspects, examples and features mentioned below can be combined in any technically possible way.

[0008] One aspect of the present disclosure provides a method of forming a gas separation contactor module, the method comprising disposing an adsorbent material on a membrane; heat treating the adsorbent material on the membrane; forming a unit frame, the frame comprising at least two opposing members; sizing the adsorbent material on the membrane to correspond to the unit frame to form an adsorbent unit; and mounting the adsorbent unit on the unit frame.

[0009] Another aspect of the present disclosure includes any of the preceding aspects, and thermally treating the adsorbent material removes liquid from the adsorbent material.

[0010] Another aspect of the present disclosure includes any of the preceding aspects, and heat treating the adsorbent material improves adhesion of the adsorbent material to the membrane.

[0011] Another aspect of the present disclosure includes any of the preceding aspects, and the installation of the sorbent unit includes attaching the membrane to the unit frame.

[0012] Another aspect of the present disclosure includes any of the preceding aspects, and the installation of the sorbent unit further includes facing the sorbent material away from the unit frame.

[0013] Another aspect of the present disclosure includes any one of the aforementioned aspects, and a periphery of the unit frame and a periphery of the adsorbent unit are formed with substantially identical configurations.

[0014] Another aspect of the present disclosure includes any one of the aforementioned aspects, and a periphery of the unit frame and a periphery of the adsorbent unit are formed in a polygonal configuration.

[0015] Another aspect of the present disclosure includes any of the aforementioned aspects, and a perimeter of the unit frame and a perimeter of the adsorbent unit are formed in a rectangular configuration.

[0016] Another aspect of the present disclosure includes any of the preceding aspects, and the attaching includes at least one of an adhesive, a thermal bond, a weld, a mechanical connection, a removable fastener, and combinations thereof.

[0017] Another aspect of the present disclosure includes any of the aforementioned aspects, and the unit frame includes a top side and a bottom side, the method further comprising attaching an adsorbent unit to the top side of the unit frame, and attaching another adsorbent unit to the bottom side of the unit frame to form a contactor module including a layer of adsorbent units attached to the top side, the unit frame, and the adsorbent unit attached to the bottom side, whereby the unit frame and the layer of adsorbent units form a frame chamber.

[0018] Another aspect of the present disclosure includes any of the preceding aspects and further includes forming an air frame, and positioning the air frame between two contactor modules.

[0019] Another aspect of the present disclosure includes any of the preceding aspects, and the frame in each contactor module is configured for heating gas flowing therein.

[0020] Another aspect of the present disclosure includes any of the preceding aspects, and an air frame disposed between the contactor modules is configured to flow a gas to be treated therein.

[0021] Another aspect of the present disclosure includes any of the aforementioned aspects, and the adsorbent material (120) includes at least one of an iron-based MOF, a zirconium-based MOF (e.g., MOF-808, such as MOF-808-Gly), an aluminum-based MOF (e.g., MOF-303), a zeolitic imidazolate framework (ZIF), an amine-containing MOF, and combinations thereof.

[0022] One aspect of the present disclosure provides a contactor module comprising a first adsorbent unit and a second adsorbent unit, each adsorbent unit comprising an adsorbent material disposed on a membrane; and a unit frame comprising a top side and a bottom side, the unit frame further comprising a perforated tube; wherein the first adsorbent unit is disposed on the top side of the unit frame and the second adsorbent unit is disposed on the bottom side of the unit frame to form a contactor module, whereby the unit frame and the layers of the first and second adsorbent units form a chamber for fluid flow.

[0023] Another aspect of the present disclosure includes any of the preceding aspects, and the chamber is configured to heat the gas flow.

[0024] Another aspect of the present disclosure includes any of the preceding aspects, and further includes forming an air frame configured for flowing a gas to be treated therein, the air frame disposed between two contactor modules.

[0025] Another aspect of the present disclosure includes any of the aforementioned aspects, and the adsorbent material includes at least one of an iron-based MOF, a zirconium-based MOF (e.g., MOF-808, such as MOF-808-Gly), an aluminum-based MOF (e.g., MOF-303), a zeolitic imidazolate framework (ZIF), an amine-containing MOF, and combinations thereof.

[0026] Another aspect of the present disclosure includes any one of the aforementioned aspects, and a periphery of the unit frame and a periphery of the adsorbent unit are formed with substantially identical configurations.

[0027] Another aspect of the present disclosure includes any of the aforementioned aspects, and a perimeter of the unit frame and a perimeter of the adsorbent unit are formed in a rectangular configuration.

[0028] Two or more aspects described in this disclosure, including those described in this Summary, can be combined to form implementations not specifically described herein.

[0029] The details of one or more implementations are set forth in the drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] These and other features of the present disclosure will be more readily understood from the following detailed description of various aspects of the present disclosure, taken in conjunction with the accompanying drawings which depict various embodiments of the present disclosure, in which:

[0031] Figure 1 A method for forming a gas separation contactor module according to an embodiment of the present disclosure is shown;

[0032] Figure 2A and Figure 2B A method for forming a scalable gas separation contactor module subassembly according to an embodiment of the present disclosure is shown;

[0033] Figure 3A and Figure 3B shows a schematic diagram of another gas separation contactor module according to an embodiment of the present disclosure;

[0034] Figure 4A and Figure 4B shows a schematic diagram of another gas separation contactor module according to an embodiment of the present disclosure;

[0035] Figure 5A and Figure 5B is a schematic diagram of a gas separation contactor module assembly according to an embodiment of the present disclosure;

[0036] Figure 6is a schematic diagram of components forming another embodiment of a gas separation contactor gas separation contactor module according to an embodiment of the present disclosure;

[0037] Figure 7 is a schematic front view of a prior art direct contact gas separation contactor module assembly;

[0038] Figure 8 is a schematic front view of an indirect contact gas separation contactor module assembly according to an embodiment of the present disclosure;

[0039] Figure 9 is a schematic front view of a tube-integrated direct contact gas separation contactor module assembly according to an embodiment of the present disclosure;

[0040] Figure 10 is a schematic front view of a tube-integrated indirect contact gas separation contactor module assembly according to an embodiment of the present disclosure;

[0041] Figure 11 shows an elevated front view of a gas separation contactor module assembly according to an embodiment of the present disclosure;

[0042] Figure 12 shows a schematic elevated front view of an embodiment of a plurality of connected gas separation contactor module assemblies according to an embodiment of the present disclosure;

[0043] Figure 13 shows an elevated front view of an embodiment of a direct contact gas separation contactor module assembly according to an embodiment of the present disclosure;

[0044] Figure 14 shows an elevated side view of a direct contact gas separation contactor module assembly according to an embodiment of the present disclosure;

[0045] Figure 15 shows an elevated front view of an embodiment of a plurality of connected indirect contact gas separation modules according to an embodiment of the present disclosure;

[0046] Figure 16 an elevated front view illustrating an embodiment of a plurality of connected direct contact gas separation module assemblies according to an embodiment of the present disclosure; and

[0047] Figure 17 An elevated front view of an implementation of a plurality of connected indirect contact gas separation modules is shown according to an embodiment of the present disclosure.

[0048] It should be noted that the drawings of the present disclosure are not necessarily drawn to scale. The drawings are intended to depict only typical aspects of the present disclosure and therefore should not be considered to limit the scope of the present disclosure. In the drawings, similar numbers represent similar elements between the drawings. DETAILED DESCRIPTION

[0049] First, in order to clearly describe the subject matter of the present disclosure, it will be necessary to select certain terms when referring to and describing the relevant parts of the gas separation contactor module, its components, and the process for manufacturing the gas separation contactor module and its components, as embodied in the present disclosure. To the extent possible, common industry terms will be used and adopted in a manner consistent with the accepted meaning of the terms. Unless otherwise indicated, such terms should be given a broad interpretation consistent with the context of this application and the scope of the appended claims. Those of ordinary skill in the art will understand that several different or overlapping terms can generally be used to refer to specific components. An object that may be described herein as a single part may include multiple components and be referenced as consisting of multiple components in another context. Alternatively, an object that may be described herein as comprising multiple components may be referred to elsewhere as a single part.

[0050] In addition, some descriptive terms may be used regularly in this article, and defining these terms at the beginning of this section should prove helpful. Unless otherwise stated, these terms and their definitions are as follows. As used herein, "downstream" and "upstream" are terms indicating the direction relative to the flow of a fluid. The term "downstream" corresponds to the direction of the flow of a fluid, and the term "upstream" refers to the direction opposite to the flow (i.e., the direction in which the flow is emitted). In the absence of any other particularity, the terms "front" and "rear" refer to directions, wherein "front" or "forward" refers to the front, and "rearward" or "rear" refers to the rear or towards the rear.

[0051] In addition, several descriptive terms may be used regularly herein, as described below. The terms "first," "second," and "third" may be used interchangeably to distinguish one component from another and are not intended to indicate the position or importance of individual components.

[0052] The terms used herein are only used to describe the purpose of specific embodiments and are not intended to limit the present disclosure. As used herein, the singular forms "a", "an" and "the" are intended to also include plural forms, unless the context clearly indicates otherwise. It will be further understood that when used in the specification, the terms "comprise" and / or "comprising" specify the presence of stated features, integers, steps, operations, elements and / or parts, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, parts and / or their groups. "Optional" or "optionally" means that the event or situation described subsequently may or may not occur, or the parts or elements described subsequently may or may not exist, and the description includes instances in which the event occurs or the parts exist and instances in which the event does not occur or the parts do not exist.

[0053] When an element or layer is referred to as being "on," "engaged to," "connected to," or "coupled to" another element or layer, it may be directly on, engaged to, connected to, or coupled to the other element or layer, or there may be intervening elements or layers. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," or "directly coupled to" another element or layer, there may be no intervening elements or layers. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0054] Metal-organic framework (MOF) is an organic-inorganic hybrid crystalline porous material that includes a regular array of positively charged metal ions surrounded by organic "linker" molecules. The metal ions form nodes that bind the "arms" of the linker molecules together, thereby forming a repeated cage structure. This cage structure forms or includes gaps, which causes the MOF to have a very large internal surface area. Synthesized MOFs can include an internal surface area greater than 7800 square meters / gram. For a more intuitive understanding, if the available surface area of ​​a teaspoon (about one gram of solid) of this material is spread out, it will cover an entire football field.

[0055] Compared to other porous materials, MOFs offer unique structural diversity, including at least: uniform pore structure; atomic-scale structural uniformity; tunable porosity; a wide range of morphologies; good mechanical and thermal stability; and flexibility in network topology, geometry, size, and chemical functionality. This unique structural diversity allows for control over MOF framework topology, porosity, and functionality. The unique structural design and tunability of MOFs can be attributed to their crystalline porous nature, which includes organic and inorganic components within a rigid periodic network structure.

[0056] refer to Figure 1 and Figure 2A-2B, a method 100 of forming a contactor module (such as heating module 250) as embodied in the present disclosure will be described. "Contactor module" is used herein as a shorthand for "gas separation contactor module" to reduce wording. A membrane 110 is provided, wherein a source of porous adsorbent material 120 including an adsorbent material (including, for example, a MOF), an additive, and at least one solvent can be placed on the membrane 110. The membrane 110 may include any suitable material. A polymer membrane is an exemplary membrane, and other membranes now known or later developed are also within the scope of the embodiments. For example, aspects of the embodiment include a membrane 110 that includes a metal component, a fabric component, a synthetic component, an artificial component, a naturally occurring component, and combinations thereof.

[0057] As described above, as embodied in the present disclosure, the adsorbent material 120 can be any porous adsorbent material, including a MOF material, such as an iron-based MOF, a zirconium-based MOF (e.g., MOF-808, such as MOF-808-Gly), an aluminum-based MOF (e.g., MOF-303), a zeolitic imidazolate framework (ZIF), an amine-containing MOF, combinations thereof, and at least one of other MOFs capable of adsorbing fluids and / or other materials from a fluid as described herein, including those now known or later developed. In certain embodiments, the adsorbent material 120 can include a polymer resin, silica, a zeolite, an amine, or a combination thereof, including those now known or later developed.

[0058] The fluids used in the embodiments include a gas to be treated that carries the material to be adsorbed, and a heated gas for regenerating the adsorbent material 120. Typically, the gas to be treated is air, and the material to be adsorbed will be carbon dioxide, but other gases and materials may be used, with corresponding changes to the specific adsorbent material 120 used. Additionally, the heated gas is typically steam or hot air, but other heated gases may be used as needed and / or appropriate. For convenience, "air" will be used to describe the gas to be treated, and "steam" will be used to describe the heated gas, but it will be understood that these specific gases are merely non-limiting examples, and other fluids may be used as needed and / or appropriate. Additionally, while "carbon dioxide" is used for convenience to describe the material to be adsorbed, it will be understood that this is a non-limiting example, and other materials may be adsorbed by making appropriate changes to the specific adsorbent material 120 used in the embodiments.

[0059] After the adsorbent material 120 is disposed on the membrane, the membrane 110 and the adsorbent material 120 then proceed to a thermal treatment assembly 130. At the thermal treatment assembly 130, the adsorbent material 120 has any liquid, such as moisture or solvent, that it contains reduced or even eliminated, thereby resulting in a drier form of the adsorbent material 120 that contains less liquid than when the adsorbent material 120 was initially disposed on the membrane 110. Additionally, at the thermal treatment assembly 130, the membrane 110 and adsorbent material 120 may be heated to improve adhesion of the adsorbent material 120 to the membrane 110.

[0060] The adsorbent material 120 on the membrane 110 can then be separated and formed into adsorbent units 150. The adsorbent units 150 can be separated at a station 160, such as by cutting the membrane 110, as described herein, so that the perimeter of the adsorbent unit 150 corresponds to the perimeter of the unit frame 220. Figure 1 As shown, the sorbent unit 150 can include an edge 111 of the membrane 110 that does not include the sorbent material 120. The edge 111 can allow the unit frame 220 to adhere to the sorbent unit 150, as described below with respect to the unit frame 220.

[0061] The perimeter of the adsorbent unit 150 and the perimeter of the unit frame 220 can be formed to have substantially the same configuration. Furthermore, as embodied in the present disclosure, the perimeter of the unit frame 220 and the perimeter of the adsorbent unit 150 can be formed to have a polygonal configuration. Furthermore, in another aspect of the present disclosure, the perimeter of the unit frame 220 and the perimeter of the adsorbent unit 150 can be formed to have a rectangular configuration.

[0062] The method 100 also includes forming a unit frame 220 for fluid flow, as described below. The unit frame 220 includes a perforated tube 200. The perforated tube 200 segments can be connected to form the unit frame 220, wherein corner pieces 221 connect the perforated tube 200 segments. Therefore, the unit frame 220 includes a periphery corresponding to the adsorbent unit 150. The corner pieces 221 are tubes that carry the fluid (air or steam) to the perforated tube 200 to move the fluid in the unit frame 220 and enter the chamber 240 defined by the unit frame 220 and the two adsorbent units 150 through the perforations 225, as described below. As embodied in the present disclosure, the unit frame 220 can be formed into a polygonal configuration. In addition, as embodied in the present disclosure, the periphery of the unit frame 220 can be formed into a rectangular configuration to align with the periphery of the adsorbent unit 150. The perforated tubes 200 used for the cell frames 220 may include plastic perforated tubes 200, polymer perforated tubes 200, metal perforated tubes 200, composite perforated tubes 200, and other materials now known or later developed. As described herein, the perforations 225 in the cell frames 220 and tubes 200 allow fluid to flow into and out of the tubes 200 and the cell frames 220. While perforated tubes are used in this example, it should be noted that unperforated tubes or even solid members may be used, as long as the gas to be treated and / or heated gas can be transported as needed in the embodiment.

[0063] Next, the method 100 positions and aligns the unit frame 220 with the adsorbent unit 150. As embodied in the present disclosure, the unit frame 220 can be positioned on and in the edge 111 of the adsorbent unit 150. Thus, according to this aspect of the present disclosure, the unit frame 220 can be permanently or removably adhered to the adsorbent unit 150 at the edge 111. The unit frame 220 can be adhered to the adsorbent unit 150 at the edge 111 by any suitable adhesion method, including adhesives, thermal bonding, welding, mechanical connections, removable fasteners, or any other fasteners now known or later developed.

[0064] The unit frame 220 includes a top side 202 and a bottom side 204 ( Figure 1 As embodied in the present disclosure, method 100 further includes forming contactor module 250 ( Figure 1). Forming the contactor module 250 includes attaching an adsorbent unit 150 to the top side 202 of the unit frame 220 and attaching another adsorbent unit 150 to the bottom side 204 of the unit frame 220, with one adsorbent unit 150 disposed on each of the two sides 202, 204, with the layer of membrane 110 contacting the unit frame 110 and defining therewith a chamber 240. By disposing the adsorbent material layer 124 as the outermost layer as shown, the contactor module 250 can be used as a heating module through which steam or another hot gas can be passed via the unit frame 220 to heat the adsorbent material layer 124, thereby releasing adsorbed carbon dioxide and, by doing so, "regenerating" the adsorbent material 120 in the adsorbent material layer 124. Thus, according to aspects of the present disclosure, the contactor module 250 includes a layer of a first adsorbent unit 150 attached to the top side 202 of the unit frame 220 and a second adsorbent unit 150 attached to the bottom side 204 of the unit frame 220, whereby the unit frame 220 and the two adsorbent units 150 form the contactor module 250 with the frame chamber 240 therebetween. It should be understood that by instead positioning the adsorbent material layers 124 facing each other in the chamber 240, the contactor module 250 can be used as an exposure module through which a gas laden with carbon dioxide can pass for adsorption of carbon dioxide by the adsorbent material layers 124. When the adsorbent material layers 124 become "full" or saturated, they can be heated as needed to release the adsorbed carbon dioxide, thereby regenerating the adsorbent material 120 in the adsorbent material layers 124 for further adsorption of carbon dioxide.

[0065] The method 100 also includes forming a scalable gas separation contactor module assembly 500 ( Figure 2A 、 Figure 2B ). As described above, for simplicity, the gas separation contactor module assembly will be referred to herein as a "contactor module assembly". The expandable contactor module assembly 500 includes a plurality of contactor modules 250 (here configured as heating modules) and an air frame 400. The air frame 400 includes a perforated tube 410. The perforated tube 410 sections can be connected to form the air frame 400, wherein the perimeter corresponds to the perimeter of the heating module 250. Corner pieces 421 connect the perforated tubes 410. Therefore, the air frame 400 includes corner pieces 421, which transport the fluid (air or steam) to the perforated tubes 410 for moving the fluid in the air frame 400, as described below. As embodied in the present disclosure, in the expandable contactor module assembly, adjacent multiple heating modules 250 and air frames 400 can share corner pieces 221 and 421 adjacent to the sides of the expandable contactor module assembly 500.

[0066] As embodied in the present disclosure, the air frame 400 can be formed into a polygonal configuration. Additionally, as embodied in the present disclosure, the perimeter of the air frame 400 can be formed into a rectangular configuration to align with the contactor modules 250. The perforated tubes 410 for the air frame 400 may include plastic perforated tubes 410, polymer perforated tubes 410, metal perforated tubes 410, composite perforated tubes 410, and other materials now known or later developed. The perforations 415 in the air frame 400 and tubes 410 allow fluid to flow into and out of the tubes 410 and the air frame 400, as described below. As described above, portions of the air frame 400 may use other components in place of the perforated tubes 410, such as unperforated tubes or even solid components, so long as the gas to be treated and / or heated gas can be transported as needed.

[0067] Scalable contactor module assembly 500 ( Figure 2A 、 Figure 2B ) includes an air frame 400 disposed between two heating modules 250. The expandable contactor module assembly 500 includes one heating module 250 disposed on either side of the air frame 400. When so arranged, the heating module 250 and the air frame 400 define an exposure chamber 420 therebetween, with the adsorbent material layer 124 at the top and bottom of the exposure chamber 420. The expandable contactor module assembly 500 is configured for the flow of steam in the heating module 250 and the flow of a gas (such as air) laden with carbon dioxide in the air frame 400 and through the exposure chamber 420. An example of operation may include passing air through the air frame 400 and the exposure chamber 420 until the adsorbent material layer 124 is "full" or saturated. Hot gas (such as steam) may then be passed through the heating module 250 to heat the adsorbent material layer 124, thereby releasing the stored carbon dioxide. Carbon dioxide adsorption may then be resumed.

[0068] Figure 2A and Figure 2B The configuration illustrates only one aspect of an embodiment. As embodied in the present disclosure, the expandable contactor module assembly 500 may include a plurality of stacked expandable contactor module assemblies 500. In this aspect of the disclosure, additional air frames 400 may be connected to one or two heating modules 250, with another heating module 250 connected to each added air frame 400, thereby creating an arrangement having alternating heating modules 250 and air frames 400. This arrangement may be repeated and may include as many heating modules 250 and air frames 400 as required for a given use case. It may be advantageous to have heating modules 250 at the ends of such an arrangement, and in embodiments, the outermost heating module 250 may have a membrane 110 on its outer side, if desired, and its adsorbent material layer 124 may also be omitted, if desired.

[0069] also, Figure 2A and Figure 2B Additional aspects of the expandable contactor module assembly 500 would include placing a second expandable contactor module assembly 500 on a "side" of the expandable contactor module assembly 500. Figure 2B , additional expandable contactor module assemblies 500 may be connected to the leftmost 510 of the expandable contactor module assembly 500 or the rightmost 511 of the expandable contactor module assembly 500 (e.g. Figure 2A and Figure 2B ), although additional module assemblies 500 may also be placed on the "closer to the viewer" side and / or the "further away from the viewer" side of the scalable contactor module assembly 500. In this configuration, the additional heating modules 250 of the added scalable contactor module assemblies 500 are aligned with each other, and the additional air frames 400 of the added scalable contactor module assemblies 500 are also aligned with each other. Thus, "layers" of the scalable contactor module assemblies 500 can be formed from left to right and towards and away from the viewer. This arrangement can be combined with the stacking described above to form a three-dimensional structure of the scalable contactor module assembly 500 that includes as many heating modules 250 and air frames 400 as may be desired and / or suitable for a particular application.

[0070] Thus, as embodied in the present disclosure, a contactor module 250 (such as a heating module) includes a first adsorbent unit 150 and a second adsorbent unit 150, each adsorbent unit 150 including an adsorbent material layer 124 disposed on a membrane 110; and a unit frame 220, wherein the unit frame 220 includes a top side 202 and a bottom side 204. The unit frame 220 with the membrane 110 forms a chamber 240 for fluid flow. According to certain aspects of the present disclosure, the chamber 240 is configured for the flow of steam to heat the adsorbent material layer 124 to release captured material.

[0071] Figure 3A and 3B An alternative form of contactor module of an embodiment is shown, here referred to as an exposed module 260, in which the adsorbent unit 150 can be attached to a solid frame 180. In an embodiment, two adsorbent units 150 can be attached to the solid frame 180 with the layers of membrane 110 facing each other. In either case, the membrane 110 of the adsorbent unit 150 can be attached to the solid frame 180 in the same manner as described above with respect to the attachment of the adsorbent unit 150 to the unit frame 220 ( Figure 1 ) is attached to the solid frame 180 in substantially the same manner as described above. Alternatively, as Figure 4A and 4BAs seen in , the frame 180 of the exposure module 260 may include a top portion 181 and a bottom portion 182 that may be placed on either side of the membrane 110 of the adsorbent unit 150 to hold the membrane 110 therebetween. For example, the top portion 181 and the bottom portion 182 may include features that interlock when assembled and force is applied, thereby clamping the membrane 110 therebetween. Such a multi-part frame may be used with or without an adhesive or other suitable and / or desired attachment means. It should also be noted that two adsorbent units 150 may be used with the multi-part frame 180 if needed and / or appropriate. Furthermore, while a four-sided solid frame 180 is shown as an example, some embodiments may alternatively use two opposing members, including Figure 4A and Figure 4B In the example shown, each of the two opposing components would in this case be a two-part component.

[0072] Figure 5A and Figure 5B The configuration of the stacked air frame 400, the adsorbent unit 150, and the unit frame 220 and an example of fluid flow therein are schematically shown. Figure 5A and Figure 5B In the example, the opposite corners are the source and exhaust of the gas in each chamber. Figure 5B As shown, and in particular, the top air frame 400 shown, a gas laden with carbon dioxide, such as air, can be supplied at a first corner 431 such that the gas flows in a first direction into each air chamber 420, such as through perforations 415, through the chamber 420 to and out of an opposite second corner 432. Similarly, as Figure 5A As shown, particularly for the top unit frame 220 shown, hot gas such as steam can be supplied at the third corner 433 so that the steam flows in a second direction into each chamber 240, such as via the perforations 225, through the chamber 240 to and out of the opposite fourth corner 434. In this configuration, the primary flow direction through each chamber is diagonal so that the steam and air flow substantially orthogonally to each other. Figure 2A and 2B The stacking and layering arrangements described by the examples shown in Figure 5A and Figure 5B , to form a structure including as many air frames 400 , adsorbent units 150 , and unit frames 220 as may be appropriate and / or desirable.

[0073] Figure 6 and Figure 8-11 Additional embodiments of contactor module assembly configurations according to aspects of the present disclosure are shown. Figure 6Components forming part of a contactor module (referred to herein as exposure module 260 ) are shown according to an embodiment of the present disclosure. Figure 7 A front view of a representative prior art direct contact contactor module assembly 290 is shown. Figure 8 A front view of a representative indirect contact tube heating contactor module assembly 625 as embodied in the present disclosure is shown. Figure 9 is a front view of a tube-integrated direct contact / heating contactor module assembly 650 according to an embodiment of the present disclosure. Figure 10 A front view of a tube-integrated indirect contact / heating contactor module assembly 675 is shown in accordance with an embodiment of the present disclosure. Figure 11 Shown Figure 8 Elevated front view of the indirect contact tube heating contactor module assembly 625. Figure 12 Shown is an elevated side view of a plurality of tube-integrated indirect heating contactor module assemblies 625 arranged and connected in two stacks adjacent to each other in accordance with an embodiment of the present disclosure. Figure 13 and Figure 14 An embodiment of a direct contact module assembly 625 is shown. Figure 15-17 Implementations of contact module assemblies 625 , 650 , 675 are shown according to embodiments of the present disclosure.

[0074] As embodied in the present disclosure, a contactor module assembly includes an adsorbent material, such as a MOF, that is arranged to be in direct contact with a fluid containing the material to be captured. The adsorbent material and the fluid "touch" or engage. A direct contact contactor module assembly brings a heat source (such as steam or another hot fluid) into direct contact with the adsorbent material to promote desorption and regeneration of the adsorbent material so that the adsorbent material can be reused for further capture. In contrast, an indirect contact contactor module assembly has an intermediate element that separates the direct contact of the adsorbent material from the heat source (such as steam or another hot fluid). For example, and as described and embodied in the present disclosure, a polymeric material can be disposed between the adsorbent material and a carrier of heat to promote desorption to regenerate the adsorbent material for further capture.

[0075] about Figure 6 , there is provided an adsorbent unit 150, such as mounted on a frame 610, which may be such as Figure 3A 、 Figure 3B 、 Figure 4A and Figure 4BAs shown in the frame 180, to form the exposure module 260. As described above, some embodiments may use a frame 180 including at least two opposing members, while other embodiments may use a four-sided frame with four members, and each member may be one part or may have two parts. As embodied in the present disclosure, the adsorbent unit 150 may be any suitable adsorbent unit. For ease of discussion, Figure 6-10 The description will refer to the above embodiments as described and provided and as Figure 1 , 3 and 4. Therefore, the formation and construction of the adsorbent unit 150 and the exposure module 260 are discussed with reference to the above description of the adsorbent unit 150.

[0076] exist Figure 6 In FIG, the components forming the components of the contactor module assembly are shown. Figure 6 , a frame 610, such as frame 180, is provided for the adsorbent unit 150. In an embodiment, the frame 610 surrounds the adsorbent unit 150 and is attached to the membrane 110. As with the above-described embodiments, the perimeter of the frame 610 and the adsorbent unit 150 can be formed into a polygonal configuration. Additionally, in another aspect of the present disclosure, the perimeter of the frame 610 and the perimeter of the adsorbent unit 150 can be formed into a rectangular configuration. It should be noted that while two layers of adsorbent material 124 are shown, either layer of adsorbent material 124 can be omitted, such as for the top or bottom of an exposed module 260 at the top or bottom of the assembly. Advantageously, two layers of adsorbent material 124 are provided by installing two adsorbent units 150 with their membrane layers 110 engaged with one another.

[0077] It is worth noting that the contactor module 250 ( Figure 1 ) and the exposure module 260 have some differences in operation. For example, the contactor module 250 ( Figure 1 ) defines a chamber 240 through which fluid passes for heating or for treating gas for adsorption, depending on the particular orientation of the adsorbent unit 150. In contrast, the exposure module 260 is configured for passing fluid over its exterior.

[0078] Figure 7A prior art direct contact contactor assembly is shown in which a plurality of contactor modules 292 are arranged between side walls 294 and have a support layer 296 on which adsorbent material 298 is present. During operation, gas to be treated passes through the assembly 290 and through the adsorbent material 298 of the contactor modules 290 into or out of the page until the adsorbent material 298 is saturated, at which point heated gas is passed through the assembly 290 out of or into the page to regenerate the adsorbent material 298. When the adsorbent material 298 is regenerated, the gas to be treated then passes through the assembly 290 into or out of the page, and the cycle repeats as needed.

[0079] Figure 8-11 Examples of contactor module assemblies 625, 650, 675 are shown that can be constructed using the exposure module 260, the two-way pipe 612, and the four-way pipe 614. Figures 8-10 In the embodiment of the present invention, the frame 610 does not convey fluid to the adsorbent material layer 124. Instead, the gas to be treated, carrying the material to be adsorbed, enters or leaves the page through the end of the assembly (not shown), and the heated fluid or heated gas (such as steam and / or hot air) is carried to the contactor module assemblies 625, 650 and 675 through one or more of the two-way pipe 612 and the four-way pipe 614. The two-way pipe 612 allows flow in both directions, and as shown in FIG. Figures 8-11 As shown, the two directions are perpendicular to the drawing. The four-way pipe 614 allows flow in four directions. Figure 9 and Figure 10 As shown, the four directions are vertical and horizontal relative to the drawing. In other words, the four flow directions in the cross-tube 614 are orthogonal relative to each other on the x-axis and the y-axis.

[0080] Figure 13 and Figure 14 An embodiment of the contactor module assembly 625 in the capture device 700 is schematically shown. Figure 13 shows an elevated end view, while Figure 14 An elevated side view is shown. Capture device 700 includes a restraint 702 for contactor module assembly 625. The restraint 702 has side walls 704 and top and bottom walls 705 that engage and / or support the frame 610 of the contactor module 625. A first plenum 706 and a second plenum 708 can be attached at opposite ends of the restraint 702, each having a first valve 710 and a second valve 712 ( Figure 14) to switch between the corresponding conduits. For example, in a capture cycle, the first valve 710 can be opened to the first source conduit 714 (such as a source of gas to be treated), and the second valve 712 can be opened to the first exhaust conduit 720. With this configuration, the gas to be treated can enter the first plenum 706, pass through the contactor module assembly 625, and exit via the second plenum 708. Similarly, during a regeneration cycle, the second valve 712 can be opened to the second source conduit 716 (such as a source of heated gas), and the first valve 710 can be opened to the second exhaust conduit. With this configuration, the heated gas can enter the second plenum 708, pass through the contactor module assembly 625, and exit via the first plenum 706. The flow direction is Figure 14 Specific examples are shown in FIG, where an exemplary gas to be treated is air and an exemplary heating gas is steam.

[0081] Figures 8-11 The embodiment also includes the ability to form expandable contactor module assemblies 625, 650, and 675. The expandable contactor module assemblies 625, 650, and 675 include multiple contactor module assemblies 625, 650, and 675 that are positioned horizontally side by side and / or vertically on top of each other as needed by the design, such as Figure 12 and Figure 15-17 The expandable contactor module assemblies 625 , 650 , and 675 can be stacked vertically or horizontally in combination with at least one other contactor module assembly 625 , 650 , and 675 to form stacked contactor module assemblies 625 , 650 , and 675 .

[0082] In certain aspects of the embodiments, such as Figure 15-17 As shown, adjacent side-by-side contactor module assemblies 625, 650, and 675 can share the two-way pipe 612 of the adjacent expandable contactor module assemblies 625, 650, and 675, or share the four-way pipe 614 of the adjacent expandable contactor module assemblies 625, 650, and 675, wherein the shared pipe, the two-way pipe 612 or the four-way pipe 614, is located at the corners of the adjacent expandable contactor module assemblies 625, 650, and 675. By positioning the two-way pipe 612 or the four-way pipe 614 at the corners of the adjacent expandable contactor module assemblies 650 and 675, the air and / or steam flow represented by arrows F in the two-way pipe 612 or the four-way pipe 614 can be efficiently conveyed to one or more of the adjacent expandable contactor module assemblies 650 and 675.

[0083] Furthermore, in certain aspects of the embodiments, one vertical direct contactor module assembly on top of another vertical direct contactor module assembly 625, 650, and 675 can share the two-way pipe 612 of the bottom or top expandable contactor module assembly 625, 650, and 675, or share the four-way pipe 614 of the bottom or top expandable contactor module assembly 625, 650, and 675. Furthermore, in certain embodiments, by positioning the two-way pipe 612 or the four-way pipe 614 at the corners of adjacent expandable contactor module assemblies 650 and 675, the air and / or steam flow represented by arrows F in the two-way pipe 612 or the four-way pipe 614 can be efficiently conveyed to one or more of the vertically oriented and / or stacked expandable contactor module assemblies 650 and 675.

[0084] In the embodiment showing the expandable contactor module assemblies 625, 650 and 675 Figure 8-10 , heated gas flow, such as hot air and / or steam flow, is represented by arrows F in either the two-way pipe 612 or the four-way pipe 614. Additionally, gas flows, such as gas flows to be treated (such as air), in the expandable contactor module assemblies 625, 650, and 675 enter the page, designated by the ends of the arrows as "x" in circles, and exit the page, designated by the tips of the arrows as circles with a dot at their centers.

[0085] Therefore, in Figure 8 , heated gas is delivered by tube 612, and the gas to be treated is shown entering the page. For example, air can pass between the exposure modules 260 and through the adsorbent material layer 124 so that the adsorbent material layer 124 can adsorb carbon dioxide. When the adsorbent material layer 124 becomes saturated with carbon dioxide, the air flow can be stopped, and hot gas (such as steam) can be delivered through the two-way tube 612 to heat and regenerate the adsorbent material layer 124. When the adsorbent material layer 124 is sufficiently regenerated, the air flow can be resumed, and the air can pass over the adsorbent material layer 124, for example, into the adsorbent material layer 124. Figure 8 , to capture more CO2. These steps can be repeated as needed. It should be understood that during regeneration, CO2 is released into the remaining air between the exposure modules 260, which can be directed to a CO2 storage system known in the art. In an embodiment, air flow can continue during regeneration, with air exiting the exposure modules 260 being directed to a CO2 storage system.

[0086] Likewise, in Figure 9, during the regeneration cycle, heated gas is transported by tube 614 and transported between exposure modules 260, and the gas to be treated is shown flowing into the page during the capture cycle. In this manner, for example, air can pass between exposure modules 260 and through adsorbent material layer 124, allowing adsorbent material layer 124 to adsorb carbon dioxide. When adsorbent material layer 124 becomes saturated with carbon dioxide, the air flow can be stopped, and steam can be passed between exposure modules 260 via tube 614 to heat and regenerate the adsorbent material layer and carry the released carbon dioxide out of contactor module assembly 650. When adsorbent material layer 124 is sufficiently regenerated, the steam flow can be stopped and the air flow can be resumed until adsorbent material layer 124 is saturated, and the cycle can be repeated as needed. It should be understood that during regeneration, carbon dioxide is released into the steam flowing between exposure modules 260, which can be directed to a carbon dioxide storage system as is known in the art.

[0087] Similarly, in Figure 10 In the embodiment of the present invention, heated gas passes through tubes 612 and 614 and between the top and bottom exposure modules 260 of the contactor module assembly 675, and the gas to be treated enters the air between the middle exposure modules 260. For example, during capture, air can pass between the middle exposure modules 260 and over the adsorbent material layer 124, allowing carbon dioxide to be adsorbed by the adsorbent material layer 124. When the adsorbent material layer 124 becomes saturated with carbon dioxide, the air flow can be stopped, and steam can be passed between the top and bottom exposure modules 260 via tube 614 to heat and regenerate the adsorbent material layer 124. When the adsorbent material layer 124 is sufficiently regenerated, the steam flow can be stopped and the air flow can be resumed until the adsorbent material layer 124 is saturated, and these steps can be repeated as needed. It should be understood that during regeneration, carbon dioxide is released into the air remaining between the middle exposure modules 260, which can be directed to a carbon dioxide storage system known in the art. In embodiments, air flow can continue during regeneration, with the air exiting the exposure modules 260 being directed to carbon dioxide storage.

[0088] Now go to Figure 15 , an embodiment of the capture device 700 includes a container 702 that houses a plurality of indirect contactor module assemblies 625. As shown, the indirect contactor module assemblies 625 can be stacked and placed side by side and can share tubes 612 at their corners. Figure 13 and 14As shown, the vessel 700 may include side walls 704 and top and bottom walls 705. A first plenum 706 and a second plenum 708 may be mounted on the ends of the vessel 702, but here, each plenum only processes gas to be processed via a first source conduit 714 and a first exhaust conduit 720, respectively. The second source conduit 716 may be connected to one or more of the tubes 612, 614 ( Figure 6 、 8 -11), which can transport heated gas between assemblies 625 and to a second exhaust conduit 718. Additional tubes can be added as appropriate or as needed to enhance steam distribution. In this configuration, for example, air can be passed through the contactor module assemblies 625 to capture carbon dioxide, and steam can be passed through the tubes to heat and regenerate the adsorbent material in the contactor module assemblies 625. In an embodiment, the flow of air can be continuous, where air exiting the device 700 during regeneration is transferred to a reservoir.

[0089] exist Figure 16 In FIG. 7 , the capture device 700 uses a plurality of connected contactor module assemblies 650 , which are tube-integrated direct contact module assemblies. Figure 16 The main body of the example is Figure 15 The body is the same as shown in , but here the cross-piece 614 can be used to pass steam directly through the contactor module assembly 650 during regeneration. Here, the air flow must be stopped during regeneration, or it may not be heated enough to regenerate.

[0090] exist Figure 17 In the capture device, a plurality of connected contactor module assemblies 675 are used, which are indirect contactor module assemblies of the tube integrated type. Figure 15 and Figure 16 The structure is very similar, but here the two-way pipe 612 and the four-way pipe 614 are as shown in FIG. Figure 10 , wherein alternating heating chambers and capture chambers are defined between the exposed modules of the contactor module assembly 675. Additionally, baffles 722 may be included to prevent air from entering the heated exposed modules of the contactor module assembly 675. In the particular illustration, six contactor module assemblies 675 are shown as three adjacent stacks of two and sharing corner tubes. Similar to Figure 10 and Figure 11 , the chamber defined by the top two and bottom two exposure modules and by every other (vertical) pair of exposure modules is a heating chamber, and a cross-piece 614 allows steam to pass therethrough during regeneration. Here, air flow can be allowed to continue during regeneration, with air exiting the second air chamber 708 during regeneration being directed to a carbon dioxide reservoir.

[0091] As will be appreciated, the technical effect of the embodiments herein is to achieve a relatively inexpensive, very scalable modular assembly for capturing airborne materials, such as carbon dioxide from air. Lower costs are achieved by using less expensive materials, such as plastic pipes or frames, etc. Scalability is achieved through the modular nature of the assembly itself. While Figure 12 and Figure 15-17 A six-component configuration is shown, but it will be appreciated that the stacks can be taller and wider, and the rows can be taller and wider. In other words, by appropriate changes to the constraints, Figure 15-17 The connected components themselves can be replicated and connected on three axes to achieve huge capture capabilities.

[0092] As used throughout the specification and claims, approximate language may be used to modify any quantitative representation that can be permissibly varied without resulting in a change in the basic function to which it relates. Accordingly, a value modified by one or more terms, such as "about," "approximately," and "substantially," is not limited to the precise value specified. In at least some cases, approximate language may correspond to the precision of the instrument used to measure the value. Here and throughout the specification and claims, range limitations may be combined and / or interchanged; unless the context or language indicates otherwise, these ranges are identified and include all subranges contained therein. "About" applied to a particular value of a range applies to both end values ​​and may indicate + / - 10% of that value unless otherwise dependent on the precision of the instrument for measuring the value.

[0093] The corresponding structures, materials, actions and equivalents of all means or step plus function elements in the following claims are intended to include any structure, material or action for performing the function in conjunction with other claimed elements for specific protection. The description of the present disclosure has been given for the purpose of illustration and description, but it is not intended to be exhaustive or to limit the disclosure to the disclosed forms. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and essence of the present disclosure. The embodiments have been selected and described in order to best explain the principles and practical applications of the present disclosure and to enable others skilled in the art to understand the various embodiments of the present disclosure with various modifications suitable for the intended specific use.

Claims

1. A method of forming a gas separation contactor module (250), the method comprising: disposing an adsorbent material (120) on the membrane (110); thermally treating (130) the adsorbent material (120) on the membrane (110); forming a unit frame (220) comprising at least two opposing members (200); sizing the adsorbent material (120) on the membrane (110) to correspond to the unit frame (220) to form an adsorbent unit (150); and The adsorbent unit (150) is mounted on the unit frame (220).

2. The method according to claim 1, wherein The adsorbent material (120) is thermally treated (130) to remove liquid from the adsorbent material (120).

3. The method according to claim 1, wherein Thermally treating (130) the adsorbent material (120) improves adhesion of the adsorbent material (120) to the membrane (110).

4. The method according to claim 1, wherein Installation of the adsorbent unit (150) includes attaching the membrane (110) to the unit frame (220).

5. The method according to claim 4, wherein The installation of the adsorbent unit (150) further includes orienting the adsorbent material (120) away from the unit frame (220).

6. The method according to claim 4, wherein: The periphery of the unit frame (220) and the periphery of the adsorbent unit (150) are formed with substantially the same configuration.

7. The method according to claim 6, wherein: The periphery of the unit frame (220) and the periphery of the adsorbent unit (150) are formed in a polygonal configuration.

8. The method according to claim 6, wherein: The periphery of the unit frame (220) and the periphery of the adsorbent unit (150) are formed in a rectangular configuration.

9. The method according to claim 4, wherein: The attaching includes at least one of an adhesive, a heat bond, a weld, a mechanical connection, a removable fastener, and combinations thereof.

10. The method according to claim 1, wherein The unit frame (220) includes a top side (202) and a bottom side (204), the method further comprising attaching an adsorbent unit (150) to the top side (202) of the unit frame (220) and attaching another adsorbent unit (150) to the bottom side (204) of the unit frame (220) to form the contactor module (250), the contactor module (120) including a layer of adsorbent units (150) attached to the top side (202), the unit frame (220), and adsorbent units (150) attached to the bottom side (204), whereby the unit frame (220) and the layer of adsorbent units (150) form a frame chamber (240).

11. The method of claim 10, further comprising forming an air frame (400), and disposing the air frame (400) between two contactor modules (250).

12. The method according to claim 11, wherein The unit frame (220) in each contactor module (250) is configured to heat the gas flowing therein.

13. The method according to claim 11, wherein The air frame (400) disposed between the contactor modules (250) is configured to allow a gas to be treated to flow therein.

14. The contactor module (250) of claim 1, wherein the adsorbent material (120) comprises at least one of an iron-based MOF, a zirconium-based MOF (e.g., MOF-808, such as MOF-808-Gly), an aluminum-based MOF (e.g., MOF-303), a zeolitic imidazolate framework (ZIF), an amine-containing MOF, and combinations thereof.

15. A contactor module (250), comprising: a first adsorbent unit (150) and a second adsorbent unit (150), each adsorbent unit (150) comprising an adsorbent material (120) disposed on a membrane (110); as well as a unit frame (220), the unit frame comprising a top side (202) and a bottom side (204), the unit frame further comprising a perforated tube (200); wherein the first adsorbent unit (150) is disposed on a top side (202) of the unit frame (220) and the second adsorbent unit (150) is disposed on a bottom side (204) of the unit frame (220) to form a contactor module (250), whereby the unit frame (220) and the layer of the first adsorbent unit and the second adsorbent unit (150) form a chamber (240) for fluid flow.

16. The contactor module (250) of claim 15, wherein: The chamber (240) is configured for the flow of heated gas.

17. The contactor module (250) according to claim 15, further comprising an air frame (400) configured for a gas to be treated to flow therein, the air frame being disposed between two contactor modules (250).

18. The contactor module (250) of claim 17, wherein: The adsorbent material (120) includes at least one of an iron-based MOF, a zirconium-based MOF (e.g., MOF-808, such as MOF-808-Gly), an aluminum-based MOF (e.g., MOF-303), a zeolitic imidazolate framework (ZIF), an amine-containing MOF, and combinations thereof.

19. The contactor module (250) of claim 15, wherein: The periphery of the unit frame (220) and the periphery of the adsorbent unit (150) are formed to have substantially the same configuration.

20. The contactor module (250) of claim 19, wherein: The periphery of the unit frame (220) and the periphery of the adsorbent unit (150) are formed in a rectangular configuration.

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